Low Power Magnetic Bearing Design for High Speed Rotating Machinery

Magnetic suspension technology has advanced to the point of being able to offer a number of advantages to a variety of applications in the rotating machinery and aerospace fields. One strong advantage is the decrease in power consumption. The design and construction of a set of permanent magnet biased, actively controlled magnetic bearing for a flexible rotor are presented. Both permanent magnets and electromagnets are used in a configuration which effectively provides the necessary fluxes in the appropriate air gaps, while simultaneously keeping the undesirable destabilizing forces to a minimum. The design includes two radial bearings and a thrust bearing. The theoretical development behind the design is briefly discussed. Experimental performance results for a set of operating prototype bearings is presented. The results include measurements of load capacity, bearing stiffness and damping, and the dynamic response of the rotor. With few exceptions, the experimental results matched very well with the predicted performance. The power consumption of these bearings was found to be significantly reduced from that for a comparable set of all electromagnetic bearings

Magnetic bearings: Fifty years of progress

Magnetic bearings are just beginning to be flown in spacecraft systems, but their development spans more than 50 years. The promise of completely noncontacting, unlubricated rotating systems operating at speeds substantially beyond the range of conventional bearings, and with no wear and virtually no vibration, has provided the incentive to develop magnetic bearing technology for many diverse applications. Earnshaw theorized in 1842 that stable magnetic suspension is not possible in all three spatial directions unless the magnetic field is actively controlled. Since that time, researchers have attempted to successfully support spinning rotors in a stable manner. Development of magnetic suspension systems over the past fifty years has included progress on both passive (permanent magnet) and active (electromagnet) systems. The improvements in bearing load capacity, stiffness, and damping characteristics are traced. The trends in rotor size, rotational kinetic energy, and improvements in active control systems capabilities are also reviewed. Implications of superconductivity on suspension system design and performance are discussed

Aerospace applications of magnetic bearings

Magnetic bearings have traditionally been considered for use in aerospace applications only where performance advantages have been the primary, if not only, consideration. Conventional wisdom has been that magnetic bearings have certain performance advantages which must be traded off against increased weight, volume, electric power consumption, and system complexity. These perceptions have hampered the use of magnetic bearings in many aerospace applications because weight, volume, and power are almost always primary considerations. This paper will review progress on several active aerospace magnetic bearings programs at SatCon Technology Corporation. The magnetic bearing programs at SatCon cover a broad spectrum of applications including: a magnetically-suspended spacecraft integrated power and attitude control system (IPACS), a magnetically-suspended momentum wheel, magnetic bearings for the gas generator rotor of a turboshaft engine, a vibration-attenuating magnetic bearing system for an airborne telescope, and magnetic bearings for the compressor of a space-rated heat pump system. The emphasis of these programs is to develop magnetic bearing technologies to the point where magnetic bearings can be truly useful, reliable, and well tested components for the aerospace community

A brushless despin drive and control for a communication satellite antenna

Spin reducing mechanical drive and control system for steering communication satellite antenn

Lubrication of space systems: Challenges and potential solutions

Future space missions will all require advanced mechanical moving components which will require wear protection and lubrication. The tribology practices used today are primarily based upon a technology base that is more than 20 years old. This paper will discuss NASA's future space missions and some of the mechanism tribology challenges that will be encountered. Potential solutions to these challenges using coatings technology will be assessed

NASA Space applications of high-temperature superconductors

The application of superconducting technology in space has been limited by the requirement of cooling to near liquid helium temperatures. The only means of obtaining these temperatures has been with cryogenic fluids which severely limit mission lifetime. The development of materials with superconducting transition temperatures above 77 K has made superconducting technology more attractive and feasible for employment in aerospace systems. Here, potential applications of high temperature superconducting technology in cryocoolers, remote sensing, communications, and power systems are discussed

Design and test of a magnetic thrust bearing

A magnetic thrust bearing can be employed to take thrust loads in rotating machinery. The design and construction of a prototype magnetic thrust bearing for a high load per weight application is described. The theory for the bearing is developed. Fixtures were designed and the bearing was tested for load capacity using a universal testing machine. Various shims were employed to have known gap thicknesses. A comparison of the theory and measured results is presented

Digital control of magnetic bearings supporting a multimass flexible rotor

The characteristics of magnetic bearings used to support a three mass flexible rotor operated at speeds up to 14,000 RPM are discussed. The magnetic components of the bearing are of a type reported in the literature previously, but the earlier analog controls were replaced by digital ones. Analog-to-digital and digital-to-analog converters and digital control software were installed in an AT&T PC. This PC-based digital controller was used to operate one of the magnetic bearings on the test rig. Basic proportional-derivative control was applied to the bearings, and the bearing stiffness and damping characteristics were evaluated. Particular attention is paid to the frequency dependent behavior of the stiffness and damping properties, and comparisons are made between the actual controllers and ideal proportional-derivative control

Titanium carbide coatings for aerospace ball bearings

In conventional ball bearings, steel to steel contacts between the balls and the raceways are at the origin of microwelds which lead to material transfer, surface roughening, lubricant breakdown, and finally to a loss in the bearing performances. To minimize the microwelding tendencies of the contacting partners it is necessary to modify their surface materials; the solid to solid collisions themselves are difficult to avoid. The use of titanium carbide coated steel balls can bring spectacular improvements in the performances and lifetimes of both oil-grease lubricated and oil-grease free bearings in a series of severe applications

Integrated Flywheel Technology, 1983

Topics of discussion included: technology assessment of the integrated flywheel systems, potential of system concepts, identification of critical areas needing development and, to scope and define an appropriate program for coordinated activity